Transport aircraft, ballistic resistant and explosive containment system

ABSTRACT

Invention includes the concept and design necessary to protect transport aircraft from catastrophic failure as the result of an on board explosive or ballistic event. Concept is to protect the flight operation personnel and flight control systems from inoperable damage resulting from an on-board event defined by the FAA NPRM Docket Number 2006-26722, Notice Number 06-09 and subsequent FAA NPRM filings. 
     Concept uses aircraft interior linings, bulkheads, interior components and commodities to shield and protect the cockpit and fight control systems from operating failure caused by an on-board explosive or ballistic event. The linings, commodities and bulkheads will be redesigned and replace existing linings and bulkheads using a combination of newly designed and developed composite ballistic materials and designs, including high strength reinforced fiber sheets with ballistic resistant core materials. These designs and materials meet or exceed the requirements of the explosive event defined in the referenced NPRM.

BRIEF SUMMARY OF THE INVENTION Overview

The events of 911 have changed our world forever. The risk and realityof terrorist attacks are part of our daily lives. The world must developmethods and tools to mitigate the effect of these attacks and we must beable and willing to utilize these tools on a daily basis.

My expertise is centered in the commercial aircraft industry. Commercialaircraft have become a focal point of terrorists because of theopportunity they present as a threatened vehicle. Aircraft arevulnerable because of the passengers and cargo. Passengers are screenednearly 100% but cargo/baggage is screened less than 40%.

After 911, all commercial aircraft in the world were required to installhardened ballistic and intrusion resistant cockpit doors by theairworthiness authorities. By November of 2002 all of the aircraft inthe world were retrofitted. Now, 5 years after 911, nothing has beendone to protect the aircraft from explosive devices in the checkedbaggage or on cargo aircraft.

Because of this situation, I believe that a newly developed device whichwould protect aircraft would represent an opportunity to build a newmarket with a new product which would save lives and help protectAmerica. I therefore have developed a design for an explosion andballistic resistant commercial aircraft cargo container.

The limitation in presenting the market with a new product of this typewas that this device was not required by the regulatory or airworthinessagencies. The airline industry does not spend money unless they have toand the ATA/IATA has powerful lobbyists to prevent expensive legislationfrom being imposed on the airline industry.

On Dec. 22, 2006, the FAA released a rulemaking proposal to require allaircraft to not only harden the cargo compartments but to harden theinteriors of the aircraft in order to protect the aircraft flightcontrol systems in the event of an explosion on board.

The FAA Rule Change Will be Implemented within 14 Months

This scenario would certainly indicate that the FAA and HomelandSecurity would expect additional terrorist threats and events in thefuture. The Presidents Report on Combating Terrorism also stronglyindicates that future terrorist threats, from multiple sources, are real

-   -   I HAVE DEVELOPED DESIGNS AND A BUSINESS MODEL TO LAUNCH AN        ENTERPRISE TO DESIGN, MANUFACTURER AND PROVIDE THESE PRODUCTS TO        THE TRANSPORT AIRCRAFT INDUSTRY    -   THESE PRODUCTS ARE NEW CONCEPTS USING STATE-OF-THE-ART MATERIALS        AND TECHNOLOGY NOT CURRENTLY INCORPORATED INTO AIRCRAFT SYSTEMS

Provisional Patent

I have been awarded a Provisional Patent from the U.S. PTO which waseffective on May 21, 2007. Within this patent application, I claimed allinterior and cargo components and systems to be covered under thispatent concept of a Ballistic and Explosion Resistant Transport Aircraftutilizing a system of hardened interiors, cargo compartments andexplosion resistant ULD containers.

The U.S. PTO Provisional Patent Registration No. is 60/931,043.

Cargo Containers

In the event that these explosive devises become an airworthinessrequirement, the 600,000 existing containers would all requirereplacement with the new hardened containers. The current cargocontainer industry does not have the capacity to accommodate arelatively short FAA implementation schedule (regardless of the designconcepts).

Congress is in the process of creating legislation which would requirethe 100% electronic inspection of all cargo and checked baggage ontransport aircraft. The technology does not exist to accommodate thisrequirement and the industry estimate is that a device may be availablein three years. However, the cost of acquisition, deployment, trainingand installation of these devices in the airports around the world wouldtake considerably longer.

Even if the devices were development to successfully 100% inspect cargoand baggage, the airline and cargo industry would not have the capacityto inspect these items in a reasonable turnaround time for commercialaircraft to continue to meet departure demands.

This Means that the Transport Aircraft Industry would Need to Reduce theNumber of Daily Departures Worldwide

If this scenario were to develop, the economic impact to one of thelargest industries in the world would be devastating. Therefore, theWhite House is already positioning to not approve the legislation to100% electronically inspect cargo and checked baggage.

This means that other tool or devices must be utilized to protect thetraveling public from on board terrorist actions.

The hardened cargo container discussed in this proposal is a proventechnology that can be produced in a short period of time and willmitigate the explosive and ballistic effect of an explosive event onboard an aircraft.

Hardened Interiors

This element of the model represents a large market segment and includesdifferent options for implementation; License or manufacture. Bothoptions provide for attractive return on investment scenarios.

The concept and design represented in the Non-Provisional Patentapplication will incorporate the replacement of existing interior shellparts and assemblies with the “hardened” newly design and constructedparts represented in the technical Specification. These new parts willmeet or exceed the ballistic resistant requirements of the FAA NPRMDocket Number 2006-26722, Notice No. 06-19 and subsequent FAA NPRMfilings.

BACKGROUND OF THE INVENTION

Transport aircraft have been a vulnerable target for terroristactivities for many years. Not until 911, did the air transport industrydo anything to help protect the aircraft from becoming a guided missilewhich could be used to attack high value targets. After these terribleevents, the FAA regulated that the cockpit doors for all transportaircraft become reinforced to provide ballistic and intrusion resistanceof the cockpit thereby deterring terrorists from gaining control of theaircraft. As you fly today, every passenger and cargo aircraft havethese hardened cockpit doors. In addition to the reinforced cockpitdoors, the air transport industry implemented the TSA (or equivalentworldwide) to check 100% of passenger carry on baggage. As of today,these are the only two actions that have been implemented on commercialaircraft to protect the public from air terrorism.

It was my belief that this threat to transport aircraft would not onlycontinue to increase but would become even a larger stage for terrorism.An example is in August of 2006, terrorists planned to attack 10aircraft simultaneously in a foiled plot last year in the UK.

Four years ago, I started to research and develop a concept and designwhich would mitigate the largest threat to aircraft. My investigationyielded that checked baggage and air cargo represented a huge threat inthat only a small percentage of baggage is checked for explosives duringthe aircraft loading cycles. This is because the ATA lobbied Congress todefeat laws that would require greater scrutiny of checked baggagebecause of the additional expense to the airlines.

My expertise is centered in the commercial aircraft industry. Commercialaircraft have become a focal point of terrorists because of theopportunity they present as a threatened vehicle. Aircraft arevulnerable because of the passengers and cargo. Passengers are screenednearly 100% but cargo/baggage is screened less than 40%.

After 911, all commercial aircraft in the world were required to installhardened ballistic and intrusion resistant cockpit doors by theairworthiness authorities. By November of 2002 all of the aircraft inthe world were retrofitted. Now, 7 years after 911, nothing has beendone to protect the aircraft from explosive devices in the checkedbaggage or on cargo aircraft.

Because of this situation, I believe that a device of this type wouldrepresent an opportunity to build a new market with a new product whichwould save lives. I therefore have developed a design for an explosionballistic resistant commercial aircraft. The design concept is notlimited to the aircraft explosive situation, but commercial aircraftrepresent a market which approaches $300,000,000 per year of cargocontainer sales which includes containers for new aircraft and a 20%annual retrofit of existing containers (attrition).

The limitation in presenting the market with a new product of this typewas that this device was not required by the regulatory or airworthinessagencies. The airline industry does not spend money unless they have to.

On Dec. 22, 2006, the FAA released a rulemaking proposal to require allaircraft to not only harden the cargo compartments but to harden theinteriors of the aircraft in order to protect the aircraft flightcontrol systems in the event of an explosion on board. This scenariowould certainly indicate that the FAA and Homeland Security would expectadditional terrorist threats and events in the future.

-   -   I HAVE DEVELOPED DESIGNS AND A BUSINESS MODEL TO LAUNCH AN        ENTERPRISE TO PROVIDE THESE PRODUCTS TO THE TRANSPORT AIRCRAFT        INDUSTRY    -   THESE PRODUCTS ARE NEW CONCEPTS USING STATE-OF-THE-ART MATERIALS        AND TECHNOLOGY NOT CURRENTLY INCORPORATED INTO AIRCRAFT SYSTEMS

Cargo Containers

The good news is that if these explosive devises become an airworthinessrequirement, the 600,000 existing containers would all requirereplacement with the new hardened containers. This represents a marketvalue of over $1,500,000,000. The current cargo container industry doesnot have the capacity to accommodate a short FAA implementationschedule.

Hardened Interiors

This segment of the model represents a $3,000,000,000 market segment andincluded different options for implementation; License or manufacture.Both options provide for attractive return on investment scenarios.

Provisional Patent

I have been awarded a Provisional Patent from the U.S. PTO which waseffective on May 21, 2007. Within this patent application, I claimed allinterior and cargo components and systems to be covered under thispatent concept of a Ballistic and Explosion Resistant Transport Aircraftutilizing a system of Systems of hardened interiors, cargo compartmentsand explosion resistant ULD containers.

The U.S. PTO Provisional Patent Registration No. is 60/931,043.

Cargo Containers

In the event that these explosive devises become an airworthinessrequirement, the 600,000 existing containers would all requirereplacement with the new hardened containers. The current cargocontainer industry does not have the capacity to accommodate arelatively short FAA implementation schedule (regardless of the designconcepts).

Congress is in the process of creating legislation which would requirethe 100% electronic inspection of all cargo and checked baggage ontransport aircraft. The technology does not exist to accommodate thisrequirement and the industry estimate is that a device may be availablein three years. However, the cost of acquisition, deployment, trainingand installation of these devices in the airports around the world wouldtake considerably longer.

Even if the devices were development to successfully 100% inspect cargoand baggage, the airline and cargo industry would not have the capacityto inspect these items in a reasonable turnaround time for commercialaircraft to continue to meet departure demands.

This Means that the Transport Aircraft Industry would Need to Reduce theNumber of Daily Departures Worldwide

If this scenario were to develop, the economic impact to one of thelargest industries in the world would be devastating. Therefore, theWhite House is already positioning to not approve the legislation to100% electronically inspect cargo and checked baggage.

This also means that other tools or devices must be utilized to protectthe traveling public from on board terrorist actions.

The hardened cargo container discussed in this proposal is a proventechnology that can be produced in a short period of time and willmitigate the explosive and ballistic effect of an explosive event onboard an aircraft.

Hardened Interiors

This segment of the model represents a large market segment and includesdifferent options for implementation. License or manufacture. Bothoptions provide for attractive return on investment scenarios.

The concept and design represented in the Non-Provisional Patentapplication will incorporate the replacement of existing interior shellparts and assemblies with the “hardened” newly design and constructedparts represented in the technical Specification. These new parts willmeet or exceed the ballistic resistant requirements of the FAA NPRMDocket Number 2006-26722, Notice No. 06-19 and subsequent FAA NPRMfilings.

TECHNICAL SPECIFICATION Explosive and Ballistic Protective BoundaryConcept

The Explosive and protective boundary concept which is the main conceptof this non-provisional patent is depicted in FIG. 1, page 37, which isincluded in the Addendum of this application.

Interior Lining Installation and Cargo Container Concept

The lining installation and cargo containment concept is the mainconcept of this non-provisional patent is depicted in the photograph inFIG. 2, page 38, which is included in the Addendum of this application.

Statement of Application that this Non-Provisional Patent is Submittedin Conjunction to a Subsequent Filing of a Provisional PatentApplication

This Application for a Non-Provisional patent is made as a subsequentfiling for Provisional Patent U.S. PTO REGISTRATION No. 60/931,043 datedMay 21, 2007.

1. Overview and History

Transport aircraft have been a vulnerable target for terroristactivities for many years. Not until 911, did the air transport industrydo anything to help protect the aircraft from becoming a guided missilewhich could be used to attack high value targets. After these terribleevents, the FAA regulated that the cockpit doors for all transportaircraft become reinforced to provide ballistic and intrusion resistanceof the cockpit thereby deterring terrorists from gaining control of theaircraft. As you fly today, every passenger and cargo aircraft havethese hardened cockpit doors. In addition to the reinforced cockpitdoors, the air transport industry implemented the TSA (or equivalentworldwide) to check 100% of passenger carry-on baggage. As of today,these are the only two actions that have been implemented on commercialaircraft to protect the public from air terrorism.

It is my belief that this threat to transport aircraft would not onlycontinue to increase but would become even a larger stage for terrorism.An example is in August of 2006, terrorists planned to attack 10aircraft simultaneously in a foiled plot last year in the UK.

Four years ago, in 2004, I started to research and develop a concept anddesign which would mitigate the largest threat to aircraft. Myinvestigation yielded that checked baggage and air cargo represented ahuge threat in that only a small percentage of baggage is checked forexplosives during the aircraft loading cycles. This is because thetechnical capabilities have not yet been developed and an affordableprocess has not been visualized which would provide a greater scrutinyof checked baggage.

Therefore, I developed a concept and design to produce an all compositecargo container that is explosive, ballistic and flammabilityresistance. The design is based on state-of-the-art composite materialswhich are utilized in new and unique combinations in commercial aircraftand apply the basic laws of physics that are used in every heat andpressure containment system in the world. The technology to constructthese products exists and does not require materials development.

In December of 2006, the US Government commenced a study to investigateincreasing the explosive and ballistic resistance of the commercialaircraft, both cargo and interiors.

The Designs that I have Created Will Meet the FAA Defined Ballistic andExplosive Threat Requirements for Transport Aircraft Interiors and CargoCompartments Reference FIGS. 1 and 2, Pages 37 & 38 Respectively, whichare Included in the Addendum to this Application

This emerging product demand is a new requirement for the aircraftindustry and represents hardening the cargo and passenger compartmentsof all transport aircraft. In addition, there are multiple derivativemarkets which would benefit from the application of this newly developedtechnology.

I have developed concepts, materials, designs, development plans andfinancing requirements which would provide for the design, qualificationand start-up of a manufacturing enterprise that would produce theseproducts in preparation for entry into commercial aircraft service.

The plan is to develop a “hardened” aircraft interior integrated systemand a composite cargo container with a patentable explosive valvingsystem using a range of composite materials wherein both series ofproducts, when combined, would be capable of withstanding the ballisticand explosive resistance required by the regulating government agencies(reference FIG. 1 in the Addendum to this Application).

This Non-Provisional Patent Application is for the patent protection ofthis concept, a complete “Transport Aircraft Explosive and BallisticResistant Containment System” which will meet all of the regulatory andGovernment requirements which are intended to protect the travelingpublic and eliminate the collateral damage caused by an airborneexplosive event.

1.1. Design Description

Design Concept

This concept provides protection of the cockpit, flight control systems,catastrophic primary structural failure of the aircraft and containmentof fire and projectiles caused as the result of an on-board explosiveevent ((Reference FIG. 1, page 37 which is included in the Addendum tothis Application). This system also provides flammability resistantnon-metallic materials and extinguishing systems within the aircraftcargo compartments (Reference FIG. 3, page 39, which is included in theAddendum to this Application). This explosive and ballistic resistantand containment system will provide economical products with the minimumweight impact to the aircraft.

1.1.1. Cargo Containers

Current Designs

The conventional materials of construction for existing Unit LoadDevices (ULD) are aluminum sheets riveted to welded aluminum structureswhich are attached to pallets. Several problems exist with this type ofconstruction.

-   a. Aluminum processing and material costs are increasing primarily    because Bauxite mining and processing is becoming more expensive due    to labor and energy costs.-   b. The primary container/pallet companies are linked to aluminum raw    material processors and/or mining operations. This creates a    competitive raw material costing issue.-   c. Repair and overhaul of the ULD is expensive, time consuming and    requires access to replacement raw materials.-   d. These materials of construction and designs do not incorporate    any explosion, ballistic or fire resistance capability or    properties.

Proposed Design

The new design concept incorporates new materials and features that donot exist in the industry today. The outline is as follows:

Materials of Construction

-   a. Composite panels manufactured from high impact/tensile strength    fiber reinforced plastic sheeting (with the possibility of    Kevlar/ballistic core). These panels may include a ballistic    Pro-Tec™ inter-ply material to enhance the resistance to    penetration/expulsion of projectiles created by the explosion.-   b. The pallet will be manufactured from aluminum or fiber reinforced    plastic perimeter extrusions which will be mechanically attached to    ballistic flooring material.-   c. All material will be flame penetration resistant and meet the    requirements of FAR 25 heat release requirements.

Design Concept

The ULD will be designed and manufactured with replaceable panels, whichare attached to extruded edge rails. The corners will be injectionmolded high-impact/tensile strength fiber reinforced thermal plastic.The attachment design will incorporate flush mounted, male/femalematching threaded Clik™ self-locking fasteners so that they will notprotrude from the basic container surfaces. This will prevent tearingand snagging during loading and handling operation. The fasteners willbe non-metallic.

The panels can be molded into curved shapes which would minimize squarecorners and reduce stress concentration areas. The square corners arenot as efficient as rounded corners for load distribution during highstress applications caused by an explosive event. All of the panels arepre-designed and manufactured using numerically controlled machinery,therefore interchangeability is assured for spare replacement parts(Reference FIG. 3, page 39, which is included in the Addendum to thisApplication).

Key Discriminating Design Features

The primary discriminating design characteristic of the cargo containeris founded on the basic gas law and physics. We are applying theprinciple of PVT to the container design. If the volume (V) remainsconstant and the temperature (T) increases, then the pressure (P)increases. Under normal explosive conditions, the restraining structuredoes not posses sufficient tensile strength to contain the rapidlyincreasing pressure which is due to the ignition of the explosivematerials wherein high heat is generated during the explosive event. Thepressure needs to find a path of least resistance and therefore,ruptures the structure in order to balance the pressure to thesurrounding atmosphere. All pressure vessels are designed with thisconcept in mind. The space shuttle Orbital Maneuvering System (OMS) usesmonopropellants, which expand at a tremendous rate relative to theatmosphere and must be relieved through a pressure regulator system.This is a proven pressure relief concept.

All High-pressure pneumatic and hydraulic systems have safety devicesincorporated into their construction to relieve unplanned pressureincreases which are created by a system failure in the control design.Typically, these pressure systems use an inexpensive static device thatoperates during the over pressure event. These devices are known asrelief valves.

The patentable concept of the relief device which I am applying thispatent for is that this device included in this application is a singlepart manufactured out of non-metallic materials. This means that thedevice will achieve the highest, most predictable reliability possible.

The Aircraft Security Product design will incorporate a series of thesevalves which will be installed in the outer panels of the ULD. Theintent of these disks is two-fold. One is to relieve the increasedpressure, which is created because of the ignition of the explosivematerials. This can be accomplished easily by the placement of the diskin the perimeter walls of the ULD. The second is that the disks cancreate a directed charge venting concept when installed in “strategic”locations around the ULD to direct the pressure venting into the largestadjacent volume of free space in the surrounding cargo hold areas. Thisconcept allows us to determine the optimal direction for thegas/pressure displacement to minimize any negative affect on the primaryaircraft structure.

The disks will be made of non-metallic materials and will be protectedin their installed positions and will easily replaceable in case ofdamage during handling and loading of the containers.

Fire Suppression

Since the phenomena of explosives are to increase the temperature of theenvironment, thereby requiring a relief path of the increased pressure,the function of a fire suppressant is also two-fold.

First of course, fire suppression systems are designed to extinguish anypotential fire inside the container due to the increased heat generatedby the explosion. The second benefit is related to the first phenomena.If the fire/heat is suppressed quickly, then the temperature will alsobe reduced rapidly, therefore minimizing the resultant pressurebuild-up.

The design plan is to incorporate a self-contained fire extinguishinggas system (Halon or equivalent) within each container (Reference FIG.3, page 39, which is included in the Addendum to this Application).These systems are highly reliable and proven for cargo and class “C”fire containment compartments in commercial aircraft today. A heatsensitive material contained within the release device will activate thefire suppression system and therefore the release of the extinguishinggas.

Tracking

One of the difficult issues with cargo containers is that they get lostor misplaced. This issue is identical to ocean freighter containers whenthey are unloaded and stored at the port of destination.

We would offer an optional capability for all containers to include theinstallation of a “hardened” GPS device into the structure of the ULD(Reference FIG. 3, page 39, which is included in the Addendum to thisApplication). This device would allow the container to be tracked andlocated anywhere in the world. This device is especially critical whentracking a potential terrorist target.

All containers would incorporate embedded bar coding that is read withhand-held downloadable data trackers. This technique is common withmoveable inventory systems currently utilized in the aircraft industrytoday.

Isometric of Typical Hardened Cargo Container Reference FIG. 3, Page 39,which is Included in the Addendum to this Application

1.1.2. Interior Linings

In order to comply with the FAA proposed ruling to protect the primaryand secondary flight control systems it is necessary to harden theaircraft interior. The only known method other than that of the AircraftSecurity Product hardened ballistic and explosion resistant interiorliners system described in this Technical Specification, would be toindividually protect the control system routings (electrical:fly-by-wire, or hydraulic), with ballistic conduit or completerelocation of the systems. The relocation of the systems would providesome assurance that either the primary or secondary systems wouldsurvive an explosive event. However, this task of protecting theimbedded systems would require the aircraft be grounded for an extendedperiod of time and the expense would be significant.

Current Designs

Current aircraft interior linings are manufactured using formedfiberglass “skins” bonded to honeycomb core. This process provides alightweight and relatively stiff product which is used for:

-   -   Sidewalls    -   Stowage Bin/Doors    -   Ceiling Panels    -   Floor Boards    -   Cockpit Bulkheads

These are the areas of the interior which would require hardening.

This Non-Provisional Patent applies to, but is not limited to, thefollowing types of interior parts and assemblies:

-   -   1.1.2.1. Interior Sidewalls    -   1.1.2.2. Interior Dado Panels    -   1.1.2.3. Cove Light Panels    -   1.1.2.4. Overhead Stowage Bin Structures    -   1.1.2.5. Overhead Stowage Bin Doors    -   1.1.2.6. Ceiling Panels    -   1.1.2.7. Cabin Lighting Panels    -   1.1.2.8. Cargo Compartment Floor Boards    -   1.1.2.9. Cargo Compartment Bulkheads    -   1.1.2.10. Floor Boards    -   1.1.2.11. Cargo Compartment Liner Panels    -   1.1.2.12. Aircraft Door Liners    -   1.1.2.13. Aircraft Door Surrounds    -   1.1.2.14. Evacuation Slide Covers    -   1.1.2.15. Cockpit Bulkheads    -   1.1.2.16. Aircraft Cabin Monuments    -   1.1.2.17. Galleys    -   1.1.2.18. Closets    -   1.1.2.19. Bulkheads    -   1.1.2.20. Dividers    -   1.1.2.21. Video Control Cabinetry    -   1.1.2.22. Lavatories    -   1.1.2.23. Aft Cabin Bulkheads    -   1.1.2.24. 9G or Aft Pressure Bulkheads    -   1.1.2.25. Any other cabin or cargo item which would require        hardening due to its location within the aircraft Interior

Proposed Design for Interior Systems

The new design would employ the concept of replacing the existinglinings with new linings manufactured from a similar group of materials,but in a different laminate construction, such as the cargo containers.Using existing materials we would create a structural laminate of fiberreinforced plastics with an explosive and ballistic resistant Pro-Tec™core to create replacement sidewall panels, ceiling panels, floorboards, stowage bin doors, cockpit bulkheads, etc., as listed above(Reference FIG. 1, page 37, which is included in the Addendum to thisApplication)

These panels will act as a “liner” for the passenger compartment whichwill provide a ballistic shield which will protect the aircraft controlsystems from damage due to ballistic projectiles that have been createdby an explosive event within the aircraft. The criteria for theballistic projectiles are defined within the FAA proposed rule extract.In addition to lining the passenger compartment with these ballistic andflammability resistant panels, the same or similar product (in adifferent form) can be used for the same purpose for cargo compartmentliners on aircraft that do not accommodate cargo containers.

These materials are proven to meet the ballistic resistance requirementscurrently defined by the FAA.

The typical sidewall construction, using the laminates described withinthis application in combination with the Pro-Tec™ core, would beballistic and flammability compliant (Reference FIG. 4, page 39, whichis included in the Addendum to this Application).

Additional design details of the related other interior components andcommodities which require hardening are also included in the Addendumsection of this application (Reference FIGS. 9A through 9 f, pages 48through 53, which is included in the Addendum to this Application).

The Integrated System of Explosion Resistant Containers with HardenedPassenger Compartment Linings and Ballistic Cockpit Walls Will Providean Explosion and Ballistic Resistant Transport Aircraft Reference FIG.1, Page 37, which is Included in the Addendum to this ApplicationAdditional Protection can be Provided by Creating Complete ExplosionProof Stowage Bins Using a Cargo Container Design Concept Reference FIG.1, Page 37, which is Included in the Addendum to this Application

1.1.3. Ballistic and Explosion Proof Cockpit Bulkheads

The reinforced cockpit bulkheads can be produced using the same designand materials of construction as the cargo container. The relief valvescan accommodate explosive decompression as well as explosive andballistic events as defined by the FAA proposed rules.

1.2. Manufacturing Processes

The quantities of parts and assemblies to support the transport aircraftindustry are significant. The expected demand would surpass the existingcapacity in the entire aircraft structures industry. New aircraftvariants are entering into production, B-787, A-380 and A-350, inaddition to rate of production increases with the existing fleet ofcommercial aircraft.

Therefore, the most efficient methods to use in the manufacturing ofthese parts and assemblies are a highly tooled process whichincorporates a large scale robotic assembly operation.

All of the products discussed within this Provisional Patent Applicationare design to be manufactured with class “A” hard tooling with CNCmachining of parts and robotic assembly. It is my belief that the demandcan be accommodated with these processes.

Existing manufacturing methods include the following processes which areavailable within the aircraft industry today.

-   -   1.2.1. Injection Molding    -   1.2.2. CNC Milling and Lathe    -   1.2.3. Plastic Extrusions    -   1.2.4. Flat Panel Press    -   1.2.5. Matched Metal Molding for Composites    -   1.2.6. Crush Core Technique    -   1.2.7. Vacuum Bag Lay-up    -   1.2.8. Heat Forming of Fiber Reinforced Plastics    -   1.2.9. Bonding and Assembly of Composite Parts    -   1.2.10. Honeycomb Core Manufacturing    -   1.2.11. Robotic Assembly and Materials Logistics Systems    -   1.2.12. Automated Inventory Control System    -   1.3. Market Analysis

The regulatory requirements will affect all transport aircraft in theworld.

This Non-Provisional Patent Application specifically includes thequantities and types of aircraft as defined in the following chart.

In addition, this Provisional Patent Application includes thereplacement of 600,000 existing cargo containers and pallets and theaddition of all new container deliveries for newly manufacturedaircraft.

Ballistic and Explosion Resistant Target Market (over 50 Pax) Apr. 1,2006 Manufacturer Aircraft Existing Fleet On Order On Option TotalBoeing 737 4,987 1,093 795 6,875 747 (−200 & above) 1,081 35 6 1,122 7571,050 0 0 1,050 767 941 14 34 989 777 552 264 71 887 787 0 342 111 453Total 8,611 1,748 1,017 11,376 McDonnel/Douglas MD-80/MD-90 1,035 0 01,035 MD-11 60 0 0 60 Total 1,095 0 0 1,095 Airbus A-300 481 12 0 493A-310 231 0 231 A-320 2,711 1,445 1,036 5,192 A-330/A-340 722 232 851,039 A-350 0 100 24 124 A-380 0 133 48 181 Total 4,145 1,922 1,1937,260 Bombardier CRJ-700 216 48 76 340 CRJ-900 41 22 12 75 Total 257 7088 415 Embraer ERJ-170 130 53 213 396 ERJ-190 39 277 221 537 Total 169330 434 933 Total Addressable Market 14,277 4,070 2,732 21,079

BRIEF DESCRIPTION OF THE DRAWINGS Drawings are Included in the “Addendumof Figures”

1. FIG. 1, Illustration (page 37 of 53 of Addendum)

-   -   a. SCD-70099002        -   I. Specification Control Drawing (SCD) which defines the            concepts for the ballistic protective shell using the            aircraft linings in conjunction with the ballistic and            explosive cargo containers.        -   II. This drawing depicts the concept of using the interior            linings of the aircraft passenger compartment as the            ballistic protective shell which prohibits the flight            control system from becoming inoperative in the case of an            on-board explosive event. This is the requirement of the FAA            NPRM 2006-2572

2. FIG. 2, Illustration (page 38 of 53 of Addendum)

-   -   a. SCD-70099003        -   I. Specification Control Drawing which illustrates the            actual aircraft installation of the ballistic and explosive            containment system that is included in the patent            application contained herein.        -   II. This picture illustrates exactly how the shell and cargo            container work together to provide the ballistic protection            and explosive resistance of the interior of commercial            transport category aircraft. This system prohibits the            flight control system from becoming inoperative in the case            of an on-board explosive event. This system meets or exceeds            the requirement of the FAA NPRM 2006-2572.

3. FIG. 3, Isometric Drawing (page 39 of 53 of Addendum)

-   -   a. Isometric of typical hardened cargo container (with        integrated fire suppression system and GPS tracking module.

4. FIG. 4, Construction Schematic of a Typical Ballistic andFlammability Compliant Sidewall (page 39 of 53 of Addendum)

-   -   a. Cross section detail of the construction of a sidewall,        composite laminate which is ballistic and flammability        resistant.

5. FIGS. 5, 5A, 5B and 5C, Drawings and Illustration of an LD2 Ballisticand Explosive Resistant Cargo Container (pages 40 & 41 of 53 ofAddendum)

-   -   a. SCD LD2-70021001 (2 pages        -   I. Source Control Drawing which defines the design and            construction details for an IATA ULD LD2 device built in            accordance with the designs, features and constructions            which are defined in the Technical Specification. These            drawings include orthographic views, 3-D illustrations and            cross sectional views, which are computer generated, and            depict the construction and materials of the Ballistic and            Explosive Resistant Cargo Containers. These drawings also            indicate the installation and the quantity of the explosive,            directed charge decompression discs.

6. FIGS. 6, 6A, 6B and 6C, Drawings and Illustration of an LD3 Ballisticand Explosive Resistant Cargo Container (pages 42 & 43 of 53 ofAddendum)

-   -   a. SCD LD3-70031001 (2 pages)        -   I. Source Control Drawing which defines the design and            construction details for an IATA ULD LD2 device built in            accordance with the designs, features and constructions            which are defined in the Technical Specification. These            drawings include orthographic views, 3-D illustrations and            cross sectional views, which are computer generated, and            depict the construction and materials of the Ballistic and            Explosive Resistant Cargo Containers. These drawings also            indicate the installation and the quantity of the explosive,            directed charge decompression discs.

7. FIG. 7, 7A, 7B, Drawings and Illustration of an LD7 Ballistic andExplosive Resistant Cargo Container (pages 44 & 45 of 53 of Addendum)

-   -   a. SCD LD7-70071001-101 (2 pages)        -   I. Source Control Drawing which defines the design and            construction details for an IATA ULD LD7 device built in            accordance with the designs, features and constructions            which are defined in the Technical Specification. These            drawings include orthographic views, 3-D illustrations and            cross sectional views, which are computer generated, and            depict the construction and materials of the Ballistic and            Explosive Resistant Cargo Containers. These drawings also            indicate the installation and the quantity of the explosive,            directed charge decompression discs.

8. FIG. 8, 8A, 8B, Drawings and Illustration of an LD7 Ballistic andExplosive Resistant Cargo Container (pages 46 & 47 of 53 of Addendum)

-   -   a. SCD LD7-70071001-103 (2 pages)        -   I. Source Control Drawing which defines the design and            construction details for an IATA ULD LD7 device built in            accordance with the designs, features and constructions            which are defined in the Technical Specification. These            drawings include orthographic views, 3-D illustrations and            cross sectional views, which are computer generated, and            depict the construction and materials of the Ballistic and            Explosive Resistant Cargo Containers. These drawings also            indicate the installation and the quantity of the explosive,            directed charge decompression discs.

9. FIG. 9A, Cross Sectional Drawings of a Ballistic and ExplosiveResistant Interior Lining and Cockpit Bulkhead (page 48 of 53 ofAddendum)

-   -   a. SCD 70099001-101 Sidewall Panel Design and Construction (1        page)        -   I. Sidewall Cross Section Drawing which defines the design            and construction details for the ballistic and flammability            resistant design, features and construction materials which            are defined in the Technical Specification. These drawings            include cross sectional views, which are computer generated,            and depict the construction and materials of the typical            sidewall panel.

10. FIG. 9B, Cross Sectional Drawings of a Ballistic and ExplosiveResistant Interior Lining and Cockpit Bulkhead (page 49 of 53 ofAddendum)

-   -   a. SCD 70099001-103 Cockpit Bulkhead Panel Design and        Construction (1 page)        -   I. Cockpit Bulkhead Cross Section Drawing which defines the            design and construction details for the ballistic and            flammability resistant design, features and construction            materials which are defined in the Technical Specification.            These drawings include cross sectional views, which are            computer generated, and depict the construction and            materials of the typical cockpit bulkhead panel.

11. FIG. 9C, Cross Sectional Drawings of a Ballistic and ExplosiveResistant Stowage Bin Door (page 50 of 53 of Addendum)

-   -   a. SCD 70099001-105 Bin Door Panel Design and Construction (1        page)        -   I. Bin Door Cross Section Drawing which defines the design            and construction details for the ballistic and flammability            resistant design, features and construction materials which            are defined in the Technical Specification. These drawings            include cross sectional views, which are computer generated,            and depict the construction and materials of the typical bin            door panel.

12. FIG. 9D, Cross Sectional Drawings of a Ballistic and ExplosiveResistant Floor Board (page 51 of 53 of Addendum)

-   -   a. SCD 70099001-107 Floor Board Panel Design and Construction (1        page)        -   I. Floor Board Panel Cross Section Drawing which defines the            design and construction details for the ballistic and            flammability resistant design, features and construction            materials which are defined in the Technical Specification.            These drawings include cross sectional views, which are            computer generated, and depict the construction and            materials of the typical floor board panel.

13. FIG. 9E, Cross Sectional Drawings of a Ballistic and ExplosiveResistant Interior Ceiling Panel (page 52 of 53 of Addendum)

-   -   a. SCD 70099001-109 Ceiling Panel Design and Construction (1        page)        -   I. Ceiling Panel Cross Section Drawing which defines the            design and construction details for the ballistic and            flammability resistant design, features and construction            materials which are defined in the Technical Specification.            These drawings include cross sectional views, which are            computer generated, and depict the construction and            materials of the typical ceiling panel.

14. FIG. 9F, Cross Sectional Drawings of a Ballistic and ExplosiveResistant Cargo Liner Panel (page 53 of 53 of Addendum)

-   -   a. SCD 70099001-109 Cargo Liner Panel Design and Construction (1        page)        -   I. Cargo Liner Cross Section Drawing which defines the            design and construction details for the ballistic and            flammability resistant design, features and construction            materials which are defined in the Technical Specification.            These drawings include cross sectional views, which are            computer generated, and depict the construction and            materials of the typical cargo liner panel.

1. This claim is for the concept of the entire and complete TransportAircraft Ballistic and Explosive Resistant Containment System as definedin this application for a Non-Provisional Patent. This claim is for acomplete protective aircraft explosive and ballistic protection systemusing the cabin interior systems and components described in theTechnical Description, when manufactured in accordance, or reasonablefacsimile of, the designs and/or materials described in this applicationfor a non-provisional patent, as being in compliance with the FAA NPRM2006-26722.
 2. The claim is for the concept, design, application, andsuitability, materials of construction and certification of theballistic resistant aircraft passenger interior lining system. This newand unique to the application for protection of transport aircraft. Theclaim is that this concept is new and proprietary to Gary Reece as theinventor, designer and architect of this system. This system has neverbeen used in serial production of commercial aircraft and the inventorclaims all rights for the usage of this concept for the protection ofthe flight control systems during and after an explosive event on-boardthese aircraft. These designs, materials and concept are specificallyintended to meet the requirements of the Federal AviationAdministrations requirement to protect the operability of the aircraftbefore, during and after an on-board explosive event as defined in theFAA Notice of Proposed Rule Making, Docket Number 2006-26722, allnotices and amendments and as released as a final version by the FAA forthe requirement to be incorporated as an airworthiness safety directivein all commercial and/or transport aircraft.
 3. This claim is for theunique design and concept of materials technology application for theaircraft ULD types of devices used in commercial aircraft for thetransport of goods, baggage and cargo in transport aircraft that aredefined in this Non-Provisional Patent Application. The concept of theTransport Aircraft Ballistic and Explosive Resistant Containment Systemwill protect the structural integrity of the aircraft, enabling for safelanding in the case of an on-board explosive event. The concept utilizesan all composite cargo container which incorporates a series of static,non-metallic explosive decompression discs which are used to direct theexplosive pressure wave to areas of larger space volume within the cargocompartment. This device is different than most existing types ofexplosive decompression devices because it is a static device, withoutmoving parts. This allows the device to be designed to accommodatevirtually any magnitude of explosive event and to react in a timenecessary to vent the pressure wave. Other devices are mechanical innature and therefore, do not react in a short enough timeframe toadequately vent this increased pressure.